High-strength insulated building panel with internal stud members

ABSTRACT

The invention is directed to a building panel which has structural integrity. A plurality of stud members with opposed side surfaces and opposed end surfaces extend from a first face of the panel toward a second face. The plurality of stud members are spaced from each other and extend in a direction which is essentially parallel to each other. A rigid foam fills the volume of the panel which is not filled by the plurality of stud members. The rigid foam is bonded to at least one side surface of each of the plurality of stud members. The bonding of the rigid foam to the plurality of stud members results in a stable and strong panel which is capable of accommodating large shear loads.

FIELD OF THE INVENTION

The present invention relates to a building panel which has structuralintegrity. In particular, the invention is directed to a panel in whicha foam is bonded to at least one side surface of each of a plurality ofstud members resulting in a stable and strong panel which is capable ofaccommodating large shear loads.

BACKGROUND OF THE INVENTION

The construction industry is continuously attempting to find ways toreduce the time, cost, and labor associated with the construction of astructure, such as a wall, room, floor, ceiling and roof. Conventionalstick building is labor-intensive, involving as separate steps, buildingthe frame, erecting the frame, applying external sheathing and buildingwrap, followed by installing thermal insulation, typically fiberglassbatts or blown-in cellulose. This practice generally results in lessthan optimal insulation because materials are inherently limited ininsulating properties and construction practices are variable.

Techniques used to reduce the time, cost, and labor associated with theconstruction of a structure include prefabrication of various portionsof a structure. Once the portion of the structure is fabricated, it isthen transported to the construction site for placement in its intendedlocation. One problem with such techniques is that the prefabricatedportion of the structure is constructed with conventional materialsusing the techniques that would be used on the construction site.Another problem with these techniques is that the prefabricated portionis subject to damage during its transportation to the construction site.

These techniques typically also require that the structural integrity ofthe prefabricated portion of the building is derived solely from theframe of the prefabricated portion. In some instances, the structuralintegrity of the prefabricated portion of the building and the buildingitself is further derived from the specific way a prefabricated portionneeds to be assembled with another portion of the building usingconnections, fasteners, and other coupling mechanisms specific to usingthe prefabricated portion.

Structural insulated panels (“SIPs”) are an increasingly common materialused in the construction of residential homes and other structures.Conventional SIPs have a sandwich-type structure, and comprise twosheets typically of a wood-based material, such as plywood or orientedstrand board (“OSB”), that are bonded to an inner slab or foaminsulation. Expanded polystyrene (“EPS”) is typically used for theinsulation, with extruded polystyrene and polyurethane foam sometimesbeing used. The bonded sandwich structure of SIPs has been demonstratedto provide comparable strength to conventional walls consisting of alumber stud frame filled with slabs of fiberglass insulation. SIPs aretypically fabricated as sheets of a standard size (e.g. 4 feet by 8feet), which can then be cut to size on-site as needed prior toinstallation.

A number of SIP designs have been considered. For example, U.S. Pat. No.6,279,287 to Meadows discloses a prefabricated building panel thatincludes first and second side panel members. A thermally insulatingcore is disposed between the panel members. A first panel end surfaceincludes a pair of spaced projections defining a channel-way, while asecond panel end surface includes a pair of spaced channels separated bya plug. Two adjacent building panels may be interconnected by engagingthe pair of projections at the first end with the pair of channels andplug at the second end.

U.S. Pat. No. 6,599,621 to Porter discloses a flat structural panel forbuilding construction that includes an inner insulating core of plasticfoam and a pair of opposed outer facings, or sheets, bonded to theinsulated core. One of the outer facings is of gypsum composite, orgypsum fiberboard, while the other outer facing is of a specialplastic-impregnated OSB. The gypsum and OSB facings form the inner andouter surfaces of the panel. The facings provide high tensile strength,with the gypsum composite or fiberboard facing also providing resistanceto fire and insects.

U.S. Patent Application Publication No. 20060117689 to Onken et al.discloses an insulated structural panel formed with a rigid foam core, aplurality of vertical hat channels on either face of the rigid foamcore, and horizontal top and bottom L-channels on either face of therigid foam core. The plurality of vertical hat channels on opposingfaces of the rigid foam core is connected so as to compress the rigidfoam core, thus adding structural strength to the insulated structuralpanel.

Although the axial and bending strengths of SIPs are known to be high,conventional SIPs typically require additional support along both theirtop and bottom surfaces. This support is typically provided by eitherone or more longitudinal strips of lumber secured to the top and bottomsurfaces of the SIPs (commonly referred to as a “plates”), or U-shaped,longitudinally extending bands secured to the top and bottom surfaces ofthe SIPs. While the plates and bands contribute to the overall strengthof the SIPs, they add to the quantity of material used in theirconstruction and thereby increase cost.

Accordingly, it is an object to provide a novel structural insulatedpanel which can be installed with conventional tools, and which has bothexceptional structural and thermal insulating properties while beinglight weight, easily handled, dimensionally stable and of a standardmodular size.

SUMMARY OF THE INVENTION

The invention is directed to a modular panel that possesses very highR-value insulating properties and high load-bearing and shear resistancethat far exceeds that normally achieved with conventionalstick-building. The modular building panel combines all necessaryfunctions—structure, maximum insulation, vapor barrier, dimensionalstability and consistency—in a single product that installs with thesame tools and skills as employed in conventional stick building. In asingle construction step the entire wall and/or roof are completed andweather proof, ready for the finishing materials.

One aspect of the invention is directed to a building panel which hasstructural integrity. The panel has a first face and an oppositelyfacing second face. A pair of panel end walls and a pair of panelsidewalls extend between the first face and the second face. A pluralityof stud members with opposed side surfaces and opposed end surfacesextend from the first face toward the second face. The plurality of studmembers are spaced from each other and extend in a direction which isessentially parallel to each other. A rigid foam fills the volume of thepanel which is not filled by the plurality of stud members. The rigidfoam is bonded to at least one side surface of each of the plurality ofstud members. The bonding of the rigid foam to the plurality of studmembers results in a stable and strong panel which is capable ofaccommodating large shear loads.

Another aspect of the invention is directed to a panel having structuralintegrity for use in floors, ceilings, walls and/or roofs of astructure. The panel has a first face and an oppositely facing secondface. A pair of panel end walls and a pair of panel sidewalls extendbetween the first face and the second face. A plurality of stud memberswith opposed side surfaces and opposed end surfaces extend from thefirst face toward the second face. The plurality of stud members arespaced from each other and extend in a direction which is essentiallyparallel to each other. A rigid foam fills the volume of the panel whichis not filled by the plurality of stud members. A facing materialextends across the first face of the panel. The facing material isbonded to the rigid foam. The bonding of the rigid foam to the pluralityof stud members and to the facing material results in a stable andstrong panel which is capable of accommodating large shear loads.

Another aspect of the invention is directed to a method of manufacturinga building panel. A plurality of stud members is positioned in a mold ina direction which is essentially parallel to each other, each stud ofthe plurality of stud members having opposed side surfaces and opposedend surfaces. The plurality of stud members are spaced from each. Foamis injected into the mold to fill the volume of the mold which is notfilled by the plurality of stud members. Increased pressure andtemperature are applied to allow the foam to cure, become rigid and bondto at least one side surface of each of the plurality of stud members.The panel is removed from the mold. The bonding of the rigid foam to theplurality of stud members results in a stable and strong panel which iscapable of accommodating large shear loads.

Other features and advantages of the present invention will be apparentfrom the following more detailed description of the preferredembodiment, taken in conjunction with the accompanying drawings whichillustrate, by way of example, the principles of the invention.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of a building panel, the panel having foampositioned between and bonded to stud members.

FIG. 2 is a perspective view of the building panel of FIG. 1 with afacing material positioned on a first surface of the building panel.

FIG. 3 is a perspective view, similar to that of FIG. 1, illustratingconduits provided in the building panel.

FIG. 4 is a cross-sectional view, taken along line 4-4 of FIG. 1,showing the foam in cooperation with the stud members, the stud membersextending across the entire width of the building panel.

FIG. 5 is a cross-sectional view, similar to that of FIG. 4, of a firstalternate embodiment of the building panel, showing the foam incooperation with the stud members, the stud members extending across aportion of the width of the building panel.

FIG. 6 is a cross-sectional view, similar to that of FIG. 4, of a secondalternate embodiment of the building panel, showing two rows of studmembers in cooperation with the foam, each row of the stud membersextending across a portion of the width of the building panel.

FIG. 7 is a perspective of a mold used in the manufacture of thebuilding panels, the mold is shown prior to injection molding, with twostud members positioned therein.

DETAILED DESCRIPTION OF THE INVENTION

According to an embodiment of the present invention, a building panel 10having structural integrity and a method of fabricating the buildingpanel are provided. The building panel 10 derives its structuralintegrity from the bond provided between a foam or foam members 20 andspaced-apart, essentially parallel stud members 30. In the orientationof FIG. 1, the stud members 30 extend vertically. However, the studmembers 30 may also extend horizontally, or in other orientations,without departing from the scope of the invention. The foam 20 may bebonded to the stud members 30 using injection molding methods, in whichthe temperature and pressure are above ambient during molding. Otherknown techniques may also be used to allow the foam 20 to bond to thestud members 30. Each panel 10 may also be fabricated with wood platesor the like (not shown) on the top and bottom ends thereof. Eachbuilding panel 10 can be coupled to other building panels 10 toconstruct a structure, such as a room, floor, ceiling and/or roof.

Exemplary embodiments of the building panel 10 having structuralintegrity are shown in FIGS. 1 through 6. In the embodiment of FIGS. 1and 4, building panel 10 has a first side surface 12, an opposite facingsecond side surface 14, and opposed end walls 16, 18. The building panelshown includes three stud members 30 and three foam members 20, howeverother numbers of stud members 30 and foam members 20 may be used. Thestud members 30 (as best shown in FIG. 4) have oppositely facing sidesurfaces 32, 34 and oppositely facing end surface 36, 38 which extendbetween the side surface 32, 34. The stud members 30 may be constructedfrom one of metal, aluminum, wood and plastic including, but not limitedto steel studs, engineered lumber or similar manufactured wood compositestuds, I-joists, studs formed from finger-jointed lumber, or hollowpipes or tubes in place of wood studs. In an embodiment of the presentinvention, the stud members 30 may be configured as a conventional stud,a c-shaped stud, an interlocking stud, or the like. In an embodiment ofthe present invention, the foam members 20 are provided between the studmembers 30 and are bonded to respective side surface 32, 34 of the studmembers 30 to provide increased structural integrity to the panel 10, aswill be more fully described.

In an embodiment shown in FIGS. 1 and 4, the end surface 36, 38 of eachof the stud members 30 extend to the side surfaces 12, 14 of the panel10. A respective stud member 30 is positioned at the end wall 16. Theother end wall 18 has no stud member, but is instead made an end of arespective foam member 20. The panel 10 is typically configured withthree stud members 30, one located at and forming one edge or end wall16 and two additional stud members 30 located at 16 and 32 inches,respectively, with the opposite edge or end wall 18 consisting of thefoam member 20, finished to mate squarely with another panels stud edge.

The foam may be made of any material having the appropriate thermalinsulating, bonding and strength characteristics, including but notlimited to a polyurethane, polyisocyanurate or other materials as may beappropriate for achieving other properties. For example, a dense fillermaterial may be added to the polyurethane foam to increase mass anddensity for improved sound isolation.

The foam may be of a closed cell structure of expanded polyurethane,which consists of a network of closed pockets of air trapped in thepolyurethane. This closed cell structure results in the foam insulationbeing both airtight, which is beneficial for thermal insulation, andimpermeable to moisture, which prevents the occurrence of water-relateddamage such as rotting and mould growth that could otherwise occur in“open cell” insulation materials such as fiberglass.

The density of the foam 20 may be controlled such that the panels 10properties of weight, effective R-value, porosity, load and shearstrength, and the like, may be altered to meet other requirements. Thefoam 20 may have a variable-density such that the higher density may belocated at the exposed, unprotected edge or end wall 18 to confergreater resistance to damage in handling.

An exemplary building panel 10 according to the invention is a 4 foot by8 foot by 3.5 inch thick panel comprised of standard 2 by 4 (thedimensions of which are 3.5 inches by 1.5 inch by 8 feet) parallel woodstud members 30 located on 16 or 24 inch centers. The foam 20 is moldedinto a matrix of rigid polyurethane foam having an approximate R-valueof 7.2 per inch such that the depth of the stud members 30 determinesthe thickness of the panel 10 and the length of the stud members 30determines the length of the panel 10. The use of conventional studmembers 30 and their spacing is consistent with standard framingpractice. The panels 10 are compatible with all building materials,construction methods and tools currently used in the constructionindustry. Its 4-foot width is consistent with all constructionprotocols.

Other exemplary panels 10 (not shown) may be made with full stud members30 on both end walls 16, 18 of the panels 10 or with half stud memberson both end walls 16, 18 such that when two panels 10 are assembled, thetwo half stud members form a full stud member. The panels 10 may be madein lengths greater or shorter than 8 feet, may be fabricated with anyspacing between stud members 30 and any number of stud members 30.Typical common alternatives include 2 by 6 stud members spaced on 16 or24 inch centers. Other alternatives include panels made with 2 by 8, 2by 10 or 2 by 12 timber studs and lengths to 20 feet or greater. Suchpanels may be used in certain cathedral ceiling constructions. Forexample a panel fabricated from 2 by 8 lumber will have an effectiveR-value of 52. The panel may be installed directly on the rafters,providing structural support as well as insulation, thereby enabling thefinish roofing materials to be installed directly.

Referring to FIG. 2, the panel 10 is faced on one or both side surfaces12, 14 with a foil, film or other facing material 40. The film 40 may bebonded to the foam members 20 and/or to the end walls 36, 38 of the studmembers 30. The lack of the foil or film 40 does not compromise thepanel's 10 strength and would only slightly reduce its effectiveR-value. The foil or film 40 may provide an enhanced moisture barrierand may also act as a barrier between the injected foam and an interiormold surfaces as the panel 10 is manufactured, thereby facilitating theremoval of the panel 10 from the mold, as will be more fully describedbelow. The film 40 may be fiberglass-reinforced aluminized Mylar film.The use of other facing materials include, but are not limited to, sheetmetal, gypsum board, plywood, laminate, OSB, fabric, plastic film, andthe like.

As illustrated in FIG. 3, the panels 10 may be made or fabricated withchannels, vias or conduits 50 molded in place to accommodate wiring,plumbing or air handling functions, including the hardware therefore.The conduits 50 extend vertically, horizontally or in any otherdirection required. Additionally panels 10 can be custom fabricated toinclude window and door openings (not shown). Utility boxes and the likecould be molded in place. By molding the foam 20 in forms whichaccommodate these features, the density of the foam 20 can be variedaround these sections to provide the proper thermal insulation required.In an alternate embodiment, an air space or conduit is provided betweenthe foam 30 and a respective side surface 12, 14 of the panel 10. Inthis embodiment, the foam insulation 30 partially fills the panel 10,its thickness regulated to fill the panel during manufacture from oneside, leaving the air space of predetermined thickness between the foamand the side surface of the panel 10. Panels of this construction may beuseful for roof assemblies where ridge vents are employed to provideventilation.

Referring to FIGS. 5 and 6, other alternative embodiments are shown. Inboth embodiments, the stud members 30 of the panels 10 do not extendacross the entire width of the panel 10. In these embodiments, the studmembers 30 are surrounded by foam 20 on both side surfaces 32, 34 and onone end surface 36, thereby providing a thermal break. In certain highenergy efficiency constructions, exterior walls are built with doublestud members 30 (FIG. 6), staggered such that a layer of foam 30 orinsulation is imposed between a respective side surface 12, 14 of thepanel 10 and a respective end wall 36, 38 of the stud members 30. Thisbreaks the thermal pathway that the stud members 30 provide. As shown inFIG. 6, panels 10 may be fabricated with two parallel rows of studmembers 30 arranged such that alternating stud members 30 defineopposite faces so that no stud member 30 is in contact with both sidesurface 12, 14 of panels 10. One such embodiment is a 5.5 inch thickpanel which contains two parallel rows of 2 by 4 stud members.

The panels of the present invention may be made by a molding process.Referring to FIG. 7, the stud members 30 are positioned a mold 80 of theinternal dimensions of the finished panel. The reactive foam is injectedor co-injected into the mold, such that the reactive foam fills thevolume of the mold not occupied by the stud members 30. If foil or film40 is to be positioned on one or both side surfaces 12, 14, the foil orfilm 40 is placed within the mold before the reactive foam is injected.The foil or film 40 forms a barrier between the reactive foam and theinside faces of the mold 80, thereby facilitating the removal of thefinished panel 10 from the mold. As is known in the molding industry,the mold 80 is positioned in a press assembly or the like, such thatpressure is applied to the outside of the mold which is sufficient tomaintain the dimensions of the mold as the foam is injected therein.Other known methods of holding the mold in position may be used. Onceinjected into the cavity of the mold, the foam cures and bonds with theside surfaces 32, 34 of the stud members 30. The foam also bonds withthe foil or film 40 is such foil or film is present in the mold. Thedensity of the foam is controlled by the choice of components of thefoam injected and their ratio and by the curing temperature, curingpressure, curing time and the quantity introduced into the mold. Suchcomponents may include, but are not limited to polyol and isocyanate.The parameters may be selected from data provided by the manufacturer orsupplier of the foam components and the specifications of the mixinghead. In the alternative, the panels 10 may be molded through the use ofa continuous molding process production line in place of the individualmold process producing an identical or similar product and function.

The closed-cell, rigid polyurethane foam provides exceptional insulationper unit thickness, surpassing fiberglass and cellulose, and beingformed and cured in the mold, provides a continuous, void-free structurefor maximum insulation value at minimum thickness.

The panels 10 of the present invention provide both exceptionalstructural and thermal insulating properties while being of relativelylight weight, easily handled, dimensionally very stable and are ofstandard modular size. The use of standard dimension stud members 30assures that all building codes are met.

The formation of the panels 10 by molding the stud members 30 into afoam matrix 20 provides maximum insulating value while the intimatebonding of the foam 20 to the stud members 30 results in exceptional andunexpected load-bearing properties. The addition of the film 40 on oneor both side surface 12, 14 provides an additional heat reflectingbenefit while ensuring that air infiltration is virtually eliminated.The exceptional thermal insulating property of the foam 20 allows wallsand roofs to be built at lower thicknesses while achieving greaterR-values than possible with fiberglass of cellulose insulatedstructures. The low density of the foam 20 results in panels 10 of lightweight, greatly simplifying handling by carpenters. The moldedconstruction of the panels 10 locks the stud members 30 in place andeliminates any warping that is characteristic of conventionalstick-built assemblies. The exceptional strength of the panels 10 withrespect to shear load may eliminate the need for external sheathing thatis required for stick building. This can save considerable cost andlabor in framing a building.

The panels 10 may be pre-assembled into full wall sections off-site andtransported to the building location to enable faster framing of thestructure, which would facilitate construction in unfavorable weatherconditions or could extend the length of the building season. The panels10 may be configured to construct modular buildings, wall and roofcomponents, and shipped to the site in a single package. Theirstructural properties, quick assembly and relatively light weight are anadvantage for handling in emergency shelter situations. The exceptionalthermal insulating properties of the panels 10 enable their use inrefrigerating and cold-storage buildings where they provide bothstructure and insulation in a single step.

The panels 10 of the present invention may be used for floors, walls,ceilings and roofs in the construction of residential and lightcommercial and industrial buildings using the same methods, tools andskills that carpenters employed in conventional stick-buildingconstruction. In addition, the panels 10 may be used as interior wallpartitions to provide rapid construction, ease of subsequentlyrelocating walls and to provide improved sound isolation between rooms.

While the invention has been described with reference to a preferredembodiment, it will be understood by those skilled in the art thatvarious changes may be made and equivalents may be substituted forelements thereof without departing from the scope of the invention. Inaddition, many modifications may be made to adapt a particular situationor material to the teachings of the invention without departing from theessential scope thereof. Therefore, it is intended that the inventionnot be limited to the particular embodiment disclosed as the best modecontemplated for carrying out this invention, but that the inventionwill include all embodiments falling within the scope of the appendedclaims.

1. A building panel having structural integrity, the panel comprising: afirst face and an oppositely facing second face, a pair of panel endwalls and a pair of panel sidewalls extend between the first face andthe second face; a plurality of stud members having opposed sidesurfaces and opposed end surfaces, the plurality of stud members extendfrom the first face toward the second face, the plurality of studmembers are spaced from each other and extend in a direction which isessentially parallel to each other; a rigid foam, the rigid foam fillsthe volume of the panel which is not filled by the plurality of studmembers, the rigid foam is bonded to at least one side surface of eachof the plurality of stud members; whereby the bonding of the rigid foamto the plurality of stud members results in a stable and strong panelwhich is capable of accommodating large shear loads.
 2. The buildingpanel as recited in claim 1, wherein the rigid foam is a closed-cellpolyurethane foam which is injection molded between the stud members toprovide a continuous, void-free structure for maximum insulation valueat a minimum thickness of the panel.
 3. The building panel as recited inclaim 1, wherein the rigid foam has a variable density whereby thehigher density is located at exposed, unprotected edges to confergreater resistance to damage in handling.
 4. The building panel asrecited in claim 1, wherein the first face has a layer of facingmaterial which extends across the first face to increase the insulationvalue of the panel.
 5. The building panel as recited in claim 4, whereinthe facing material is a fiberglass reinforced aluminized polyesterfilm.
 6. The building panel as recited in claim 4, wherein the facingmaterial is bonded to the rigid foam.
 7. The building panel as recitedin claim 1, wherein a first side wall is formed from one of theplurality of stud members and a second side wall is formed from therigid foam.
 8. The building panel as recited in claim 1, wherein theside walls are formed from respective stud members of the plurality ofstud members.
 9. The building panel as recited in claim 1, wherein afirst row of the plurality of stud members is provided which extend fromthe first face, the first row of the plurality of stud members has therigid foam provided between the first row of the plurality of studmembers and the second face, whereby a thermal break is provided toprevent a thermal pathway across the width of the panel through theplurality of stud members.
 10. The building panel as recited in claim 9,wherein a second row of the plurality of stud members is provided whichextend from the second face, the second row of the plurality of studmembers has the rigid foam provided between the second row of theplurality of stud members and the first face, the second row of theplurality of stud members is staggered from the first row of theplurality of stud members whereby a thermal break is provided to preventa thermal pathway across the width of the panel through the plurality ofstud members.
 11. The building panel as recited in claim 1, whereinconduits are provided in the panel, the conduits are provided toaccommodate wiring, plumbing or air flow through the panel.
 12. A panelhaving structural integrity for use in floors, ceilings, walls or roofsof a structure, the panel comprising: a first face and an oppositelyfacing second face, a pair of panel end walls and a pair of panelsidewalls extend between the first face and the second face; a pluralityof stud members having opposed side surfaces and opposed end surfaces,the plurality of stud members extend from the first face toward thesecond face, the plurality of stud members are spaced from each otherand extend in a direction which is essentially parallel to each other; arigid foam, the rigid foam fills the volume of the panel which is notfilled by the plurality of stud members; a facing material extendingacross the first face of the panel, the facing material is bonded to therigid foam; whereby the bonding of the rigid foam to the plurality ofstud members and to the facing material results in a stable and strongpanel which is capable of accommodating large shear loads.
 13. The panelas recited in claim 12, wherein the rigid foam is a closed-cellpolyurethane foam which is injection molded between the stud members toprovide a continuous, void-free structure for maximum insulation valueat a minimum thickness of the panel.
 14. The panel as recited in claim12, wherein the rigid foam has a variable density whereby the higherdensity is located at exposed, unprotected edges to confer greaterresistance to damage in handling.
 15. The panel as recited in claim 12,wherein the facing material is a fiberglass reinforced aluminizedpolyester film.
 16. The panel as recited in claim 12, wherein the facingmaterial extends across the second face to increase the insulation valueof the panel, the facing material is bonded to the rigid foam and to theplurality of stud members of the second face.
 17. A method ofmanufacturing a building panel having structural integrity, the methodcomprising; positioning a plurality of stud members in a mold in adirection which is essentially parallel to each other, each stud memberof the plurality of stud members having opposed side surfaces andopposed end surfaces; spacing the plurality of stud members from each;injecting a foam into the mold to fill the volume of the mold which isnot filled by the plurality of stud members; applying increased pressureand temperature to allow the foam to cure, become rigid and bond to atleast one side surface of each of the plurality of stud members;removing the panel from the mold; whereby the bonding of the rigid foamto the plurality of stud members results in a stable and strong panelwhich is capable of accommodating large shear loads.
 18. The method asrecited in claim 17, wherein the density of the foam injected into themold has a variable density whereby the higher density is injected atlocations which more wear will occur to confer greater resistance todamage in handling.
 19. The method as recited in claim 17, wherein afacing material is positioned in the mold, the facing material extendingacross the width of the mold, the facing material bonding with the foamwhen the appropriate pressure and temperature are applied.
 20. Themethod as recited in claim 17, wherein conduits are formed in the foamduring the molding process, the conduits are provided to accommodatewiring, plumbing or air flow through the panel.
 21. The method asrecited in claim 17, wherein a first row of the plurality of studmembers is positioned in the mold and a second row of the plurality ofstud members is positioned in the mold and is staggered and offset fromthe first row of the plurality of stud members whereby as the foam iscured, a thermal break is provided to prevent a thermal pathway acrossthe width of the panel through the plurality of stud members.